Method for controlling welding deformation of thin-walled casing product

Abstract

The application discloses a thin-wall machine case product welding deformation control method, which is realized based on a welding deformation control system and comprises the following steps: S1. initialization and preparation; the application adopts data acquisition and real-time monitoring, which is helpful for timely finding the deformation condition in the welding process, so that adjustment can be rapidly made, various means such as thermal deformation prediction, force control and temperature regulation are comprehensively used, various parameters in the welding process are comprehensively mastered, the risk of deformation is effectively reduced, the collected data in the welding process are analyzed, relevant information is extracted, optimization suggestions are formed, improvement directions are provided for future production, the influence of welding deformation is reduced, subsequent adjustment and correction processes are reduced, production efficiency is improved, the production cycle is shortened, and the production cost is reduced, the consistency and stability of production are improved by reducing the demand for adjustment and correction, and the production cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of deformation control, in particular to a thin-walled cabinet product welding deformation control method. BACKGROUND

[0002] Thin-walled cabinet products are box or container products with thin-walled structures. They are characterized by relatively thin walls and relatively complex structures, and are commonly used in the manufacturing of electronic devices, automotive parts, and household appliances. These products usually require dimensional stability and appearance quality during production, as even slight deformation can affect their functionality and appearance.

[0003] The general production process of thin-walled cabinet products includes design and engineering, material preparation, and processing and forming. Welding is a critical step in processing and forming, and is also the cause of deformation during the production of thin-walled cabinet products:

[0004] Firstly, the heat generated during welding causes thermal expansion in the welding area, leading to material deformation. After welding, residual stress may exist within the material, causing product deformation. The use of inappropriate materials or excessively thin materials can easily cause deformation. Inappropriate welding path selection or incorrect welding parameter settings can also cause deformation.

[0005] The hazards caused by welding deformation during the production of thin-walled cabinet products include unstable product dimensions, affecting assembly and use, as well as declining product appearance quality, affecting product aesthetics and market competitiveness, and even causing the product to malfunction. For products with strict size requirements, additional processing and correction procedures are needed, increasing production costs and cycle time.

[0006] Generally, traditional solutions in the welding production of thin-walled cabinet products usually rely on experience and trial-and-error, lacking precise control means, which can easily lead to a lack of real-time monitoring of key parameters during the welding process and the inability to adjust welding parameters in real time to reduce deformation. Due to the lack of precise control means, the quality and stability of the product may be low, and repeated adjustments of welding parameters or multiple corrections may be required. The production cycle of products under traditional solutions is longer, and the efficiency is lower. Additionally, additional labor and time costs are required to adjust and correct deformation during the welding process, which can increase production costs.

[0007] In summary, a thin-walled cabinet product welding deformation control method is needed to solve the above problems. SUMMARY

[0008] The purpose of the present application is to provide a thin-walled cabinet product welding deformation control method to solve the problems raised in the background.

[0009] To achieve the above object, the present application provides the following technical solutions:

[0010] The thin-walled cabinet product welding deformation control method is realized based on a welding deformation control system and includes the following steps:

[0011] S1. Initialization and preparation;

[0012] S101. Start and initialize the system;

[0013] S102. Clean and pretreat the welding area to ensure the quality of the welding surface;

[0014] S103. Calibrate the machine vision and the world coordinate system to ensure accurate collection of information of the welding area and the workpiece position;

[0015] S2. Perform welding path planning;

[0016] S201. Use machine vision to collect images of the welding area;

[0017] S202. Use image processing technology to extract welding path and weld information;

[0018] S203. Convert the welding path into a path in the machine coordinate system in combination with the world coordinate system;

[0019] S3. Perform heat conduction analysis and thermal compensation;

[0020] S301. Perform heat conduction analysis to predict possible thermal deformation during welding;

[0021] S302. Adjust the welding path or welding parameters according to the analysis results to reduce the influence of thermal deformation;

[0022] S4. Adjust force control and force feedback;

[0023] S401. Use a force sensor to measure welding force during welding;

[0024] S402. Adjust the force of the welding robot according to the sensor feedback information to reduce deformation;

[0025] S5. Perform temperature control and temperature adjustment;

[0026] S501. Use a temperature sensor to monitor the temperature in the welding area;

[0027] S502. Adjust the welding parameters according to the measured temperature data to maintain stable temperature and reduce the occurrence of thermal deformation;

[0028] S6. Real-time monitoring and adjustment;

[0029] S601. In the welding process, real-time monitoring of various parameters, including welding force, temperature;

[0030] S602. Adjust the welding path and parameters according to real-time data to maintain welding quality;

[0031] S7. Data storage and analysis;

[0032] S701. Store the data collected during the welding process in the database;

[0033] S702. Analyze the stored data to extract insights about the welding process and deformation control;

[0034] S8. End and feedback;

[0035] S801. After the welding is completed, end the welding task and close the system;

[0036] S802. Based on the data analysis results, propose improvement suggestions or optimization schemes to improve the efficiency and quality of the next welding.

[0037] The welding deformation control system includes a machine vision module, a world coordinate system module, a motion control module, a heat affected module, a force control module, a temperature control module, a data storage and analysis module, and a user interface and human-computer interaction module;

[0038] The machine vision module is used for image acquisition and image processing;

[0039] The world coordinate system module is used to measure the position and attitude of the welding workpiece;

[0040] The motion control module is used for motion planning and motion control;

[0041] The heat affected module is used for heat conduction analysis and adjustment of welding path or welding parameters;

[0042] The force control module is used to measure welding force and force feedback control;

[0043] The temperature control module is used to measure and adjust the temperature of the welding area;

[0044] The data storage and analysis module is used for data storage and analysis;

[0045] The user interface and human-computer interaction module is used to provide a graphical user interface and human-computer interaction.

[0046] Preferably, the machine vision module further includes an image acquisition unit and an image processing unit;

[0047] The image acquisition unit is used to acquire images from the welding area;

[0048] The image processing unit is used for pre-processing and analyzing the collected images to extract welding area information.

[0049] Preferably, the world coordinate system module further comprises a sensor unit and a coordinate conversion unit.

[0050] The sensor unit measures the position and attitude of the welding workpiece through one of a laser sensor or a high-precision camera.

[0051] The coordinate conversion unit is used to convert the data obtained by the sensor into a machine coordinate system, ensuring that the system understands the actual position of the workpiece.

[0052] Preferably, the motion control module further comprises a motion planning unit and a motion control unit.

[0053] The motion planning unit is used to plan the motion path of the welding robot according to the welding path and the geometry of the workpiece.

[0054] The motion control unit is used to control the motion of the welding robot to ensure precise movement according to the planned path.

[0055] Preferably, the heat influence module further comprises a heat conduction analysis unit and a heat compensation unit.

[0056] The heat conduction analysis unit is used to simulate heat conduction during welding to predict possible thermal deformation of the workpiece.

[0057] The heat compensation unit adjusts the welding path or welding parameters based on the results of heat conduction analysis to reduce thermal deformation.

[0058] Preferably, the force control module further comprises a force sensor unit and a force feedback control unit.

[0059] The force sensor unit is used to measure the welding force during welding to detect possible deformation caused by force.

[0060] The force feedback control unit is used to adjust the force of the welding robot based on the feedback information of the force sensor to reduce deformation.

[0061] Preferably, the temperature control module further comprises a temperature sensor unit and a temperature regulation unit.

[0062] The temperature sensor unit is used to measure the temperature of the welding area.

[0063] The temperature regulation unit is used to adjust the welding parameters to maintain a stable temperature based on the measured temperature data.

[0064] Preferably, the data storage and analysis module further comprises a data storage unit and a data analysis unit.

[0065] The data storage unit is used to store various collected data in a database for subsequent analysis and review;

[0066] The data analysis unit is used to analyze the stored data and extract insights related to the welding process and deformation control.

[0067] Preferably, the user interface human-computer interaction module further comprises a user interface unit and a human-computer interaction unit;

[0068] The user interface unit is used to provide a graphical user interface to display real-time data and system status;

[0069] The human-computer interaction unit allows users to interact with the system to adjust parameters or monitor the welding process.

[0070] Compared with the prior art, the present application has the following advantages: the present application adopts data acquisition and real-time monitoring, which helps to timely discover the deformation in the welding process, so that adjustments can be made quickly, the use of machine vision system for path planning and heat conduction analysis and prediction model for parameter adjustment improves the accuracy of the welding path and parameters, reduces the occurrence of deformation, and comprehensively uses heat deformation prediction, force control, temperature regulation and other means to master various parameters in the welding process, effectively reduces the risk of deformation, analyzes the data collected during the welding process, extracts relevant information, forms optimization suggestions, provides improvement direction for future production, reduces the impact of welding deformation, reduces subsequent adjustment and correction processes, improves production efficiency, shortens production cycle, reduces production cost, improves production consistency and stability by reducing the need for adjustment and correction, and reduces production cost. BRIEF DESCRIPTION OF DRAWINGS

[0071] Figure 1 Flow chart of the thin-walled case product welding deformation control method of the present application; DETAILED DESCRIPTION

[0072] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0073] Please refer to Figure 1 The present application provides a technical solution:

[0074] The method is realized based on a welding deformation control system, and comprises the following steps: S1. initialization and preparation; S2. welding path planning; S3. heat conduction analysis and heat compensation; S4. force control and force feedback adjustment; S5. temperature control and temperature adjustment; S6. real-time monitoring and adjustment; S7. data storage and analysis; S8. end and feedback.

[0075] The welding deformation control system comprises a machine vision module, a world coordinate system module, a motion control module, a heat influence module, a force control module, a temperature control module, a data storage and analysis module, and a user interface and human-computer interaction module.

[0076] It should be noted that:

[0077] The machine vision module is used for image acquisition and image processing; the world coordinate system module is used for measuring the position and attitude of the welding workpiece; the motion control module is used for motion planning and motion control; the heat influence module is used for heat conduction analysis and adjustment of the welding path or welding parameters; the force control module is used for measuring the welding force and force feedback control; the temperature control module is used for measuring and adjusting the temperature of the welding area; the data storage and analysis module is used for data storage and analysis; and the user interface and human-computer interaction module is used for providing a graphical user interface and human-computer interaction.

[0078] The machine vision module further comprises an image acquisition unit and an image processing unit; the image acquisition unit is used for acquiring images from the welding area; and the image processing unit is used for pre-processing, analyzing and extracting information of the welding area.

[0079] The world coordinate system module further comprises a sensor unit and a coordinate conversion unit; the sensor unit measures the position and attitude of the welding workpiece through one of a laser sensor or a high-precision camera; and the coordinate conversion unit converts the data obtained by the sensor into a machine coordinate system, ensuring that the system understands the actual position of the workpiece.

[0080] The motion control module further comprises a motion planning unit and a motion control unit; the motion planning unit plans the motion path of the welding robot according to the welding path and the geometric shape of the workpiece; and the motion control unit controls the motion of the welding robot, ensuring accurate movement according to the planned path.

[0081] The heat influence module further comprises a heat conduction analysis unit and a heat compensation unit; the heat conduction analysis unit simulates the heat conduction in the welding process and predicts the possible thermal deformation of the workpiece; and the heat compensation unit adjusts the welding path or welding parameters according to the results of the heat conduction analysis to reduce thermal deformation.

[0082] The force control module further includes a force sensor unit and a force feedback control unit. The force sensor unit is used to measure the welding force during the welding process and detect possible deformation caused by the force. The force feedback control unit is used to adjust the force of the welding robot according to the feedback information of the force sensor to reduce the deformation.

[0083] The temperature control module further includes a temperature sensor unit and a temperature adjustment unit. The temperature sensor unit is used to measure the temperature of the welding area. The temperature adjustment unit is used to adjust the welding parameters according to the measured temperature data to maintain a stable temperature.

[0084] The data storage and analysis module further includes a data storage unit and a data analysis unit. The data storage unit is used to store various collected data in a database for subsequent analysis and review. The data analysis unit is used to analyze the stored data and extract insights related to the welding process and deformation control.

[0085] The user interface and human-computer interaction module further includes a user interface unit and a human-computer interaction unit. The user interface unit is used to provide a graphical user interface to display real-time data and system status. The human-computer interaction unit allows users to interact with the system to adjust parameters or monitor the welding process.

[0086] Embodiments

[0087] In the implementation process, first, a welding deformation control system including a machine vision module, a world coordinate system module, a motion control module, a thermal influence module, a force control module, a temperature control module, a data storage and analysis module, and a user interface and human-computer interaction module is established.

[0088] Image acquisition and image processing are performed through the machine vision module:

[0089] The machine vision module further includes an image acquisition unit and an image processing unit. The image acquisition unit is used to acquire images from the welding area. The image processing unit is used to preprocess and analyze the acquired images and extract welding area information.

[0090] The position and attitude of the welding workpiece are measured through the world coordinate system module:

[0091] The world coordinate system module further includes a sensor unit and a coordinate conversion unit. The sensor unit measures the position and attitude of the welding workpiece through one of a laser sensor or a high-precision camera. The coordinate conversion unit is used to convert the data obtained by the sensor into a machine coordinate system to ensure that the system understands the actual position of the workpiece.

[0092] Motion planning and motion control are performed through the motion control module:

[0093] The motion control module further comprises a motion planning unit and a motion control unit; the motion planning unit is configured to plan a motion path of the welding robot according to the welding path and the geometry of the workpiece; and the motion control unit is configured to control the motion of the welding robot to ensure accurate movement according to the planned path;

[0094] The heat-affected module is configured to perform heat conduction analysis and adjust the welding path or welding parameters:

[0095] The heat-affected module further comprises a heat conduction analysis unit and a heat compensation unit; the heat conduction analysis unit is configured to simulate heat conduction during welding to predict possible thermal deformation of the workpiece; and the heat compensation unit is configured to adjust the welding path or welding parameters according to the results of the heat conduction analysis to reduce thermal deformation;

[0096] The force control module is configured to measure the welding force and force feedback control:

[0097] The force control module further comprises a force sensor unit and a force feedback control unit; the force sensor unit is configured to measure the welding force during welding to detect possible deformation caused by force; and the force feedback control unit is configured to adjust the force of the welding robot according to the feedback information of the force sensor to reduce deformation;

[0098] The temperature control module is configured to measure and adjust the temperature of the welding area:

[0099] The temperature control module further comprises a temperature sensor unit and a temperature adjustment unit; the temperature sensor unit is configured to measure the temperature of the welding area; and the temperature adjustment unit is configured to adjust the welding parameters according to the measured temperature data to maintain a stable temperature;

[0100] The data storage and analysis module is configured to store and analyze data:

[0101] The data storage and analysis module further comprises a data storage unit and a data analysis unit; the data storage unit is configured to store various collected data in a database for subsequent analysis and review; and the data analysis unit is configured to analyze the stored data to extract insights related to the welding process and deformation control;

[0102] The user interface and human-computer interaction module is configured to provide a graphical user interface and human-computer interaction:

[0103] The user interface and human-computer interaction module further comprises a user interface unit and a human-computer interaction unit; the user interface unit is configured to provide a graphical user interface to display real-time data and system status; and the human-computer interaction unit allows users to interact with the system to adjust parameters or monitor the welding process;

[0104] The thin-walled cabinet product welding deformation control method based on the above welding deformation control system comprises the following steps:

[0105] S1. Initialization and preparation;

[0106] S101. Start and initialize the system;

[0107] S102. Clean and pretreat the welding area, ensuring the quality of the welding surface;

[0108] S103. Calibrate the machine vision and world coordinate system, ensuring accurate collection of welding area information and workpiece position;

[0109] S2. Perform welding path planning;

[0110] S201. Use machine vision to collect images of the welding area;

[0111] S202. Use image processing techniques to extract welding path and weld information;

[0112] S203. Convert the welding path to the machine coordinate system path in combination with the world coordinate system;

[0113] S3. Perform heat conduction analysis and thermal compensation;

[0114] S301. Perform heat conduction analysis to predict possible thermal deformation during welding;

[0115] S302. Adjust the welding path or welding parameters based on the analysis results to reduce the impact of thermal deformation;

[0116] S4. Adjust force control and force feedback;

[0117] S401. Use force sensors to measure welding force during welding;

[0118] S402. Adjust the welding robot's force based on sensor feedback information to reduce deformation;

[0119] S5. Temperature control and temperature adjustment;

[0120] S501. Use temperature sensors to monitor temperature in the welding area;

[0121] S502. Adjust welding parameters based on measured temperature data to maintain stable temperature and reduce thermal deformation;

[0122] S6. Real-time monitoring and adjustment;

[0123] S601. Monitor various parameters in real time during welding, including welding force and temperature;

[0124] S602. Adjust the welding path and parameters based on real-time data to maintain welding quality;

[0125] S7. Data storage and analysis;

[0126] S701. Store the collected data during the welding process in a database;

[0127] S702. Analyze the stored data to extract insights about the welding process and deformation control;

[0128] S8. End and feedback;

[0129] S801. After the welding is completed, end the welding task and shut down the system;

[0130] S802. Based on the data analysis results, propose improvement suggestions or optimization schemes to improve the efficiency and quality of the next welding.

[0131] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and variations can be made to these embodiments without departing from the principles and spirit of the present application, the scope of the present application being defined by the appended claims and their equivalents.

Claims

1. A method for controlling welding deformation of thin-walled casing products. This method is based on a welding deformation control system and is characterized in that: The following steps are involved: S1. Initialization and preparation; S101. Start and initialize the system; S102. Clean and pre-treat the welding area to ensure the quality of the welding surface; S103. Calibrate the machine vision and world coordinate system to ensure accurate collection of welding area information and workpiece position; S2. Perform welding path planning; S201. Using machine vision to capture images of the welding area; S202. Using image processing technology to extract welding path and weld information; S203. Combining the world coordinate system, converting the welding path into a path in the machine coordinate system; S3. Perform heat conduction analysis and thermal compensation; S301. Perform heat conduction analysis to predict possible thermal deformation during welding; S302. According to the analysis results, adjust the welding path or welding parameters to reduce the impact of thermal deformation; S4. Adjust force control and force feedback; S401. During the welding process, a force sensor is used to measure the welding force; S402. According to the sensor feedback information, adjust the force of the welding robot to reduce deformation; S5. Perform temperature control and temperature regulation; S501. Use a temperature sensor to monitor the temperature in the welding area; S502. According to the measured temperature data, adjust the welding parameters to maintain a stable temperature and reduce the occurrence of thermal deformation; S6. Real-time monitoring and adjustment; S601. During the welding process, real-time monitoring of various parameters, including welding force and temperature; S602. Adjust the welding path and parameters according to real-time data to maintain welding quality; S7. Data storage and analysis; S701. The data collected during the welding process are stored in the database; S702. Analyze the stored data and extract parameters related to the welding process and deformation control; S8. Conclusion and feedback; S801. After welding is completed, end the welding task and shut down the system; S802. Based on the data analysis results, propose improvement suggestions or optimization plans to improve the efficiency and quality of the next welding.

2. Welding deformation control system, according to the thin-walled casing product welding deformation control method of claim 1, characterized in that, Including machine vision module, world coordinate system module, motion control module, heat impact module, force control module, temperature control module, data storage and analysis module and user interface human-computer interaction module; The machine vision module is used for image acquisition and image processing; The world coordinate system module is used to measure the position and posture of the welding workpiece; The motion control module is used for motion planning and motion control; The heat impact module is used for heat conduction analysis and adjustment of welding paths or welding parameters; The force control module is used to measure welding force and force feedback control; The temperature control module is used to measure and adjust the temperature of the welding area; The data storage and analysis module is used for data storage and analysis; The user interface human-computer interaction module is used to provide a graphical user interface and human-computer interaction.

3. The welding deformation control system according to claim 2, characterized in that: The machine vision module also includes an image acquisition unit and an image processing unit; The image acquisition unit is used to acquire images from the welding area; The image processing unit is used to preprocess and analyze the collected images.

4. The welding deformation control system according to claim 3, characterized in that: The world coordinate system module also includes a sensor unit and a coordinate conversion unit; The sensor unit is used to measure the position and posture of the welding workpiece; The coordinate conversion unit is used to convert the data obtained by the sensor into a machine coordinate system.

5. The welding deformation control system according to claim 4, characterized in that: The motion control module also includes a motion planning unit and a motion control unit; The motion planning unit is used to determine the welding path and the geometric shape of the workpiece; The motion control unit is used to control the motion of the welding robot.

6. The welding deformation control system according to claim 5, characterized in that: The heat impact module also includes a heat conduction analysis unit and a heat compensation unit; The heat conduction analysis unit is used to simulate heat conduction during welding; The thermal compensation unit is used to adjust the welding path or welding parameters.

7. The welding deformation control system according to claim 6, characterized in that: The force control module also includes a force sensor unit and a force feedback control unit; The force sensor unit is used to measure the welding force during the welding process; The force feedback control unit is used to adjust the force of the welding robot.

8. The welding deformation control system according to claim 7, characterized in that: The temperature control module also includes a temperature sensor unit and a temperature adjustment unit; The temperature sensor unit is used to measure the temperature of the welding area; The temperature regulating unit is used to adjust welding parameters to maintain a stable temperature.

9. The welding deformation control system according to claim 8, characterized in that: The data storage and analysis module further includes a data storage unit and a data analysis unit; The data storage unit is used to store the collected data in a database; The data analysis unit is used to analyze the stored data.

10. The welding deformation control system according to claim 9, characterized in that: The user interface human-computer interaction module also includes a user interface unit and a human-computer interaction unit; The user interface unit is used to provide a graphical user interface; The human-computer interaction unit allows a user to interact with the system.

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